Last week I was working with several people on data management issues for the supply chain. As I mentioned in my previous post from the ECC in Munich, there is a trend where OEMs require more and more cooperation from their suppliers. Most of these suppliers are mid-sized companies and these companies often lack the management support to implement changes top-down in an organization.

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In mid-market companies the concept for quality guarantee and consistent responses is often implemented in design data management (control the product data), a quality system (ISO,—–) and the ERP system. See also PLM and ERP culture change. As these systems could be implemented on department level, not touching each other too much, it is relative easy from the cultural point of view to implement them. Each department can optimize themselves and often the quality system is not enforcing the users to work completely different.

But who and where is innovation managed ?

Large enterprises discovered that, in order to innovate, you need to connect and analyze all information around the products they are manufacturing. In simple words they realized PLM is needed to connect everyone around the product lifecycle from the concept phase till the production and after-sales phases. For these companies PLM became the backbone for their specific knowledge – we call it IP (Intellectual Property). Big companies could implement PLM because they had the management vision, the resources (people and budget) and the top-down approach to enable (and sometimes enforce) this change.

In mid-sized companies there might be the management vision, but resources and a top-down approach are rare. When it comes to a top-down approach, often the management believes that the goal is to enforce one IT system to the organization to manage all the critical data. Naturally this is the ERP system, and ERP vendors remain claiming that they can do PLM. It is a kind of overestimation of these companies as their nature lies in processing data, resources as efficient as possible, not in being creative to find new innovations.

Innovation is not CAD design as others may believe. These beautiful 3D designs smell like innovation, but in fact before a designer could start working on a concept, a lot of work has been done before. Analysis about what is it that the market, the customers require?  What is de feedback on our current products in the field ? What is the competition doing etc, etc.

PLM requires culture change

As long as an organization remains thinking around 1 or 2 major IT systems (CAD data management and ERP) to manage all, there is no chance for PLM to be implemented successful. All departments and disciplines around the product lifecycle need to work together, change their departmental habits and learn to adapt to PLM best practices.

There is enough argumentation why to implement PLM and I believe solutions like ENOVIA SmarTeam Engineering Express are from the technology point a good start. See all related posts and comments to my previous post.

What I wanted to stress is that changes in a mid-market company are not done from the logical point of view. As the top-down vision and implementation often are not available, we are waiting for all departments to decide let’s change our way of working as we read all these beautiful benefits of PLM. This is of course not going to happen, only in advertisements.

Culture change even in mid-sized companies is a management responsibility and requires an open mind. We often forget that we have two sides in our brain. One side the logical side, analyzes all the arguments and stores them logically as good or bad. The other side of the brain, the emotional side is making the decisions, grabbing arguments that suit from the logical side in order to explain to others and ourselves why a decision is taken.

If you read books like The Language of Change (very theoretical, but the groundwork) or Blink: The power of thinking without thinking (very popular) you will understand that changes won’t happen if we stick to the traditional way of posting our arguments and keep on doing what we feel good with.

It is the management responsibility to think how to enforce a change in their companies. But as they also have a two sided brain, for that reason, management consultants were invented to reflect and discuss the emotional and logical side.

If after reading this post, you are more aware of the fact that one side of your brain fools you, then I achieved something. If however you will say “This is nonsense”, your other half of the brain has won.

Footnote:  No more words about soccer – Holland is out

This week, I was in Bruxelles conducting a Engineering Express training for ENOVIA SmarTeam resellers. The feedback I got from the participants during the training made me again more aware from the culture change needed or dreamed about in the small and medium manufacturing enterprises.

As I wrote before in PLM and ERP – the culture change , there is for sure a conservative vision in the small and medium enterprises to stay with their major IT systems they invested in, usually ERP and (3D) CAD.

From the bigger enterprises and reading all the analyst reports, many of us project that the small and medium enterprises also need PLM in the same way as the bigger enterprises, but then in a more packaged, ready to use manner, instead of a custom implementation guided by PLM experts like the bigger enterprises did.

So ENOVIA SmarTeam Engineering Express is a prepackaged solution bringing PLM closer to the mid-market. However during the training many of the questions were not around the capabilities of the Engineering Express, but more about why do we(customers) need to use the same approach as bigger enterprises, why do we have the same needs?

Where big companies focus on defining and implementing processes in order to have a predictable outcome, I noticed in talking with SMB companies, they are proud of explaining they exist without these processes enforced, but work in a more flexible, human task oriented manner.

If we look to a classical ECR/ECO process, we see in bigger companies there are several steps to be identified to react on a outside request (the ECR) and to implement it (ECO).

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An Engineering Change Request (ECR) process

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An Engineering Change Order (ECO) process

In smaller companies the ECR process is already embedded in one singe ECO process. Sometimes a formal (email) based activity takes place before a change is requested and implemented. One of the participants in the course – a manufacturing company – mentioned that they had the notice of a CCB in their company but all engineering change requests were sent to the CCB by email and as the CCB was meeting on a weekly base, this was the process to filter engineering change requests.

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So here is the question: Big enterprises need processes to remain manageable – like a big tanker needs a predefined methodology to navigate through a harbor. Small and medium enterprises are more relying on their flexibility and they need a reliable and sustainable way to react – like a small ship in a harbor – as it can react quickly there is no need for the anticipation, still the capability to change direction is needed.

So are small and medium enterprises that behave like small ships in the harbor ?

If yes, they need to remain open for change as going straight ahead at the end will lead to a collision – and the challenge remains to make the (culture) change.

Or if no, how can you provide small and medium enterprises with means that enforce change without creating the overhead that compromises the flexibility ?

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I am looking forward to comments and thought on this question – please post them.

However my first priority tonight is to survive in Milan where the match Italy-France will decide who continues to the next round in the European Soccer Championship. Worst case in parallel the Netherlands looses from Romania, in that case both Italy and France are gone and this might be my last post:)

Hoping to write my next post at the end of this week.  ciao – adieu

ECC
Last week I visited the ECC in Munich, a conference where around 1000 people attended. It was an excellent event for networking and being in touch with customers, implementers of the ENOVIA brand. The V6 announcement and demonstrations were the major key-note sessions and they showed the focus on real global collaboration for big enterprises.

In the industrial tracks I followed the Aerospace / Defense track (approx 80 attendees), where European companies like Airbus, Aermacchi and Messier-Dowty gave their status and vision on their core development processes, supported by sessions from IBM and Dassault Systems.

imageInteresting to learn from this session was that all agree that the classical hierarchical structure in the supply chain will disappear and that it will be more and more a network of suppliers working together, with much more responsibility and risk sharing for the supply chain partners.  This higher responsibility and risk requires supplier to work with a PDM system too, and Airbus stated that for future contracts with suppliers this is a must – either integrated or interfaced.

Suppliers who do not meet these quality standards by having PLM implemented will not get new contracts anymore and in the next three years we will see a change in the supplier network and collaboration technology, based on solutions upcoming from Dassault and other software suppliers.

On the second day I attended the ENOVIA SmarTeam track (approx 100 people) where beside the current roadmap an interesting scenario was explained how the smaller and medium enterprises could work on V5 but thanks to the coexistence capabilities of V6 could collaborate with V6 companies or even inside their company could work on both levels in the future. It will be interesting to follow this approach.

Finally on June 9th the European soccer championship started. The Dutch team did not perform well during the qualification rounds and we were all afraid for the real tournament.

But miracles still happen – enjoy

This week I visited a company, which was very successful in what they were doing with their products – actually everyone is running to keep up the demand from their customers. I have seen this typical situation all around the world. People are too busy to implement new and more efficient ways of working (introducing PLM in the cases where I am involved) and hanging to their old ways of working. Companies went through their first (and second) ERP implementation and this became the dominant system where everyone has to connect to, trying to avoid another maybe painful implementation.  

Implementing PLM requires a different vision; it is not just connecting the CAD documents through a PDM system with ERP. It means that you need to start to think about company-wide processes, not optimization of a department. The biggest discussion often is around who owns the creation of an item number and its status. Companies have invested in the past in all kind of complex numbering systems to identify items by its number (as there was no IT system to support that). Then the ERP system became the source for item definition although the initial creation was done by engineers.

It is clear there is a change needed in the way companies connect their engineering environment with their production environment. Doing it the old way still requires many flExcels (as Excel is the most flexible tool to pass information) and people chasing, modifying and checking Excels before entering them in the ERP system.

ERP vendors tried to avoid this change by extending their systems with PLM functionality. As PLM and ERP are two complete different disciplines, would you go to a construction company to have your new house designed or would you hire an architect first.

Of course, ERP systems can become familiar with PLM, but if it is not your key activity, you will never get the 100 % feeling for it. For example, the company I visited tried to implement BlueStar, as this was a direct linked PLM system on top of Axapta. The reason the implementation failed was not a technical issue although there were some performance issues. Nevertheless, it is not hard to write the data in the right table even with some delay, but aligning the world of PLM and ERP together was the problem. Engineering works with revisions (major / minor) they work with statuses, which are not known in the ERP world.

Conclusion:

Let PLM systems do what they are design for and implement them through PLM specialists. Next, connect the PLM and ERP system for a streamlined company wide process. Look for the basics at the ENIAC SmarTeam Engineering Express.

In one of my next posts, I will address PLM-ERP integration best practices, but now I am going to pack my suitcase in order to be in Munich for an exciting ENOVIA Customer Conference

The connection between PLM systems and ERP systems has kept many companies busy for many years. As both systems manage items in their system, all kind of battles are fought on ownership, redundancy of data and more. Last week I was involved in four different cases, which demonstrates this topic is very actual, and as most of the companies involved were in the mid-market, it shows also these companies are no in the phase of implementing and extending PLM within the organization.

In the first case, which I will comment here, it was a big enterprise using ENOVIA SmarTeam and SAP. As SAP has their own PLM module, the initial push was of course to use SAP all over, however the company considered the SAP PLM module not powerful and flexible enough for their engineering environment. For that reason the battle around the items and mainly the BOM for Manufacturing started.

The manufacturing BOM is usually the start point for production and the source for the ERP system to start production (and planning). For that reason, ERP systems claim ownership for this BOM, although the definition of the BOM is all based on engineering information within the PLM system.  As ERP systems are already established for many years, companies are familiar with defining the manufacturing BOM in their system, often a labor-intensive job as data needs to be collected from the engineering department, often in the form of spreadsheets.

PLM systems are designed to manage the manufacturing BOM , connecting all information within the system. This requires however, a change in the way people and a company is working. Engineers have more responsibility to enter complete data – there is no one to review and complete the data afterwards and combined with the lack of flexibility that people had before with Excel this lead to a cultural refusal from the floor.

If the management realizes that managing the manufacturing BOM in the PLM system will lead to less errors, a shorter time to production and less labor cost, they will push this approach top-down. This happened in many big PLM centric enterprises.  In smaller companies, this value is not visible for the management as often users, the IT department or the ERP team will pinpoint that the PLM system does not suit their needs, as it requires a change in working (their best practices).

Culture change will only come in the mid-market when PLM concepts become a commodity for companies too. The change will come, driven by ENOVIA SmarTeam with their mid market solutions. But we all know changes take time.

I will talk in my next posts in more details on PLM-ERP issues. FYI the customer mentioned in the beginning decided to keep the manufacturing BOM definition in SAP as this is what they understood and people decided not to take the risk with PLM.  

Culture change takes time ….

Virtual Dutchman

Why Virtual ? This is my first post and in the future, I will update you about my experiences in the world of PLM. Those of you not familiar with PLM I suggest searching for the definition on the web and you will find many almost similar definitions – a neutral one you can find on Wikipedia. The main goal behind PLM is that by managing all steps of the product lifecycle from concept through development until even destruction, the company will be able to optimize and integrate all steps and information. This combined with best practices on how to develop, release and benefit from customer feedback will lead to higher revenues and a more competitive position for such a company.

Most of the PLM software companies provide their solutions around a 3D CAD system, as the 3D CAD model is the understandable representation of a product. Here we see the virtual products and with analysis and simulation software we can test these products even before they are produced. Mobile phones undergo virtual crash tests; cars crash virtually and as I learned, even diapers are tested virtually.

Some PLM companies like Dassault Systèmes and Siemens UGS go even beyond the 3D CAD and integrate the whole manufacturing process initially through software to provide a virtual production process. This allows companies to fix (virtual) errors in the production process and the prototype even before a single product is manufactured in the real world. The time and costs savings of this virtualization allow companies to respond faster and better than their competitors. This change to define a complete virtual product and production process is costly and only affordable by the big enterprise but for sure this trend will continue.

With the introduction of PLM 2.0 Dassault Systèmes even introduced another extension to PLM, the involvement of the customer, experiencing the virtual product before it even exists. The 2.0 version is a reference to WEB 2.0 bringing WEB content to be influenced by the consumer. In the same analogy PLM 2.0  brings the world of product design to be influenced immediately by the customer, wherein the past customers only could review and select from existing products.

Look at the See What You Mean movie.

A virtual world seems to be a future trend, with possible virtual consumers. Currently the trend to virtualization can be compared with teenage sex; they all talk about but …….

As a Dutchman working in the real world, I am targeting to become a virtual Dutchman. This allows me to experience things I have never done and dared before. But before reaching this goal I will entertain you with my observations around PLM and look forward to real discussions.

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  1. Unknown's avatar
  2. Håkan Kårdén's avatar

    Jos, all interesting and relevant. There are additional elements to be mentioned and Ontologies seem to be one of the…

  3. Lewis Kennebrew's avatar

    Jos, as usual, you've provided a buffet of "food for thought". Where do you see AI being trained by a…

  4. Håkan Kårdén's avatar